541E-OM1010-00
OPERATION MANUAL
CRAWLER CRANE
Serial No. 11001 and up
Unsafe use of this machine may cause serious injury or death. Operators must read this manual before operating this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it.
NOTICE
CONTENTS
ITEM
PageINTRODUCTION １－ １
1. INTRODUCTION 1－ ２
2.FOR SAFE USE OF MACHINE １－ ３
3. MACHINE OVERVIEW １－ ４
3.1 SPECIFIED OPERATIONS １－ ４
3.2 MACHINE CONFIGURATION １－ ４
3.3 MACHINE FUNCTIONS １－ ５
4. QUALIFICATION FOR OPERATION １－ ６
4.1 QUALIFICATION FOR CRANE OPERATION １－ ６
5. TERMINOLOGY １－ ７
5.1 DEFINITIONS OF TERMS １－ ７
5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT １－ ８
5.3 RATED TOTAL LOAD CHART １－ ９
6. NECESSARY INFORMATION FOR SERVICE １－１２
SAFETY ２－ １
1. BASIC PRECAUTIONS ２－ ２
1.1 PRECAUTIONS FOR BEFORE STARTING OPERATION ２－ ２ 1.2 PREPARARATIONS OF SAFETY OPERATION ２－ ３
1.3 PRECAUTIONS FOR FIRE PREVENTION ２－ ５
1.4 PRECAUTIONS WHEN GETTING ON OR OFF ２－ ６
1.5 OTHER PRECAUTIONS ２－ ７
2. DRIVING RELATED PRECAUTIONS ２－ ８
2.1 PRECAUTIONS FOR JOBSITE ２－ ８
2.2 PRECAUTIONS WHEN ENGINE STARTING ２－１１ 2.3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE ２－１３ 2.4 PRECAUTIONS WHEN WORKING WITH CRANE ２－１６
3. TRANSPORT PRECAUTIONS ２－２４
4. TOWING PRECAUTIONS ２－２５
5. MAINTENANCE PRECAUTIONS ２－２６
5.1 PRECAUTIONS BEFORE MAINTENANCE ２－２６
5.2 PRECAUTIONS DURING MAINTENANCE ２－２９
6. SAFETY LABEL LOCATIONS ２－３３
OPERATION ３－ １
1. MACHINE EACH SECTION ３－ ２
1.1 MACHINE EACH UNIT ３－ ２
ITEM
Page2. EXPLANATION OF DEVICES ３－ ５
2.1 MACHINE MONITOR ３－ ５
2.1.1 EMERGENCY STOP ITEMS ３－ ６
2.1.2 GAUGE AND METER ３－ ８
2.1.3 PILOT DISPLAY ３－１０
2.2 SWITCHES ３－１１
2.3 MOMENT LIMITER (OVERLOAD DETECTOR ) ３－１４
2.3.1 MOMENT LIMITER CONFIGURATION ３－１４
2.3.2 FUNCTION OF MOMENT LIMITER ３－１５
2.3.3 MOMENT LIMITER OPERATIONS ３－１７
2.3.4 NAMES OF MOMENT LIMITER DISPLAY UNIT ３－１９
2.3.5 MOMENT LIMITER FUNCTIONS ３－２８
2.3.6 MOMENT LIMITER STARTING STATUS ３－３０ 2.3.7 MOMENT LIMITER WORKING ENVELOPE SETTING ３－３０ 2.3.8 PICK & CARRY/STAITIONARY MODE SELECT SWITCH ３－３１ 2.3.9 MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH ３－３２ 2.3.10 MOMENT LIMITER CAUSES OF ERRORS AND ACTIONS TO BE TAKEN ３－３３
2.4 OVER HOIST DETECTOR ３－３４
2.5 CONTROL LEVERS AND PEDALS ３－３５
2.6 COVERS WITH LOCK ３－４０
2.7 ENGINE HOOD ３－４１
2.8 FUSES ３－４３
2.9 FUSIBLE LINK ３－４４
2.10 OPERATION MANUAL STORAGE ３－４４
2.11 GREASE GUN HOLDER ３－４４
2.12 POWER SUPPLY FOR OPTIONS ３－４５
3. MACHINE OPERATIONS AND CONTROLS ３－４６
3.1 CHECKING/ADJUSTING BEFORE STARTING ENGINE ３－４６
3.1.1 VISIBLE CHECKS ３－４６
3.1.2 CHECKING BEFORE STARTING (CHECKING BEFORE OPERATION) ３－４９ 3.1.3 OPERATIONS/CHECKING BEFORE STARTING ENGINE ３－５９ 3.1.4 CHECKING AFTER STARTING ENGINE ３－６１
3.2 STARTING ENGINE ３－６４
3.2.1 NORMAL STARTING ENGINE ３－６４
3.2.2 STARTING ENGINE IN COLD WEATHER ３－６５
3.3 OPERATIONS AFTER STARTING ENGINE ３－６７
3.3.1 ENGINE WARM-UP OPERATION ３－６７
3.4 STOPPING ENGINE ３－６９
3.5 BREAKING-IN MACHINE ３－７０
ITEM
Page3.7 STARTING/MOVING/STOPPING MACHINE ３－７２
3.8 STEERING MACHINE ３－７６
3.9 SWINGING ３－７８
3.10 CAUTIONS BEFORE OPERATING THE CRANE ３－７9 3.11 OPERATIONS BEFORE OPERATING THE CRANE ３－８０
3.12 CRANE OPERATION POSTURE ３－８２
3.13 HOOK RAISING/LOWERING OPERATION ３－８３ 3.13.1 NORMAL HOOK RAISING/LOWERING OPERATION ３－８３ 3.13.2 HOOK RAISING OPERATION BY HOOK STOWAGE SWITCH ３－８４
3.14 BOOM DERRICKING OPERATION ３－８５
3.15 BOOM TELESCOPING OPERATION ３－８６
3.16 SWING OPERATION ３－８７
3.17 STOWAGE OPERATION OF CRANE ３－８８
3.17.1 CRANE OPERATION FOR TEMPORARY HOOK BLOCK STOWAGE ３－８８ 3.17.2 CRANE OPERATION FOR REGULAR HOOK BLOCK STOWAGE ３－９１ 3.18 DO’S AND DON’TS DURING OPERATION ３－９３
3.19 PICK AND CARRY OPERATION ３－９５
3.19.1 SAFETY PRECAUTIONS FOR PICK AND CARRY OPERATION ３－９５ 3.19.2 POSTURE FOR PICK AND CARRY OPERATION ３－９６ 3.19.3 OPERATIONS DURING PICK AND CARRY OPERATION ３－９７ 3.19.4 RELEASING PICK AND CARRY OPERATION POSTURE ３－９７
3.20 OPERATION OF BLADE ３－９８
3.20.1 PRECAUTION OF BLADE OPERATION ３－９８
3.20.2 OPERATION OF BLADE ３－９９
3.20.3 WORKING WITH A BLADE ３－９９
3.21 PARKING MACHINE ３－１００
3.22 MACHINE INSPECTION AFTER DAILY WORK ３－１０１
3.22.1 BEFORE STOPPING ENGINE ３－１０１
3.22.2 AFTER STOPPING ENGINE ３－１０１
3.22.3 LOCKING ３－１０１
3.23 CAUTIONS IN TRAVELING ３－１０２
4. HANDLING WIRE CABLES ３－１０４
4.1 BENCHMARK FOR REPLACING WIRE CABLES ３－１０４ 4.2 WINCH WIRE CABLE FALL MODE AND RATED TOTAL LOAD ３－１０６ 4.3 WHAT TO DO WITH TWISTED WINCH WIRE CABLE ３－１０７
5. TRANSPORTATION ３－１１０
5.1 LOADING/UNLOADING ３－１１１
5.1.1 LOADING ３－１１２
5.1.2 SECURING MACHINE ３－１１４
ITEM
Page5.2 LIFTING MACHINE ３－１１６
5.2.1 LIFTING THE MACHINE IN THE BOOM LOWERED POSTURE ３－１１６ 5.2.2 LIFTING THE MACHINE IN THE BOOM RAISED POSTURE ３－１１８
6. HANDLING IN COLD WEATHER ３－１２０
6.1 PREPARING FOR LOW TEMPERATURE ３－１２０
7. LONG TERM STORAGE ３－１２３
7.1 BEFORE STORING IT MACHINE ３－１２３
7.2 DURING STORAGE ３－１２３
7.3 AFTER STORAGE ３－１２３
8. TROUBLES AND ACTIONS ３－１２４
8.1 RUNNING OUT FUEL ３－１２４
8.2 PHENOMENA THAT ARE NOT FAILURES ３－１２４
8.3 TOWING THE MACHINE ３－１２５
8.4 DISCHARGED BATTERY ３－１２５
8.4.1 CAUTIONS IN BATTERY HANDLING ３－１２５
8.4.2 BATTERY REMOVAL AND INSTALLATION ３－１２６
8.4.3 CAUTIONS IN BATTERY CHARGING ３－１２７
8.4.4 STARTING ENGINE WITH BOOSTER CABLE ３－１２８
8.4.5 STARTING ENGINE ３－１２９ 8.5 OTHER TROUBLE ３－１３０ 8.5.1 ELECTRICAL COMPONENTS ３－１３０ 8.5.2 CHASSIS ３－１３０ 8.5.3 ENGINE ３－１３１ 8.5.4 MOMENT LIMITER ３－１３２
8.5.5 OVER HOIST DETECTOR ３－１３２
INSPECTION AND MAINTENANCE ４－ １
1. PRECAUTIONS REGARDING MAINTENANCE ４－ ２
2. BASIC MAINTENANCE ４－ ４
3. LEGAL INSPECTION ４－ ７
4. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ４－ ８
5. CONSUMABLES ４－ ９
6. OTHER COMPONENTS ４－１０
7. USE OF FUEL, COOLANT AND LUBRICANT ４－１１
7.1 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURES ４－１１
8. TIGHTENING TORQUE SPECIFICATIONS ４－１３
8.1 STANDARD TIGHTENING TORQUE LIST ４－１３
ITEM
Page10. MAINTENANCE PROCEDURES ４－１６
10.1 INITIAL 500 HOUR MAINTENANCE ４－１６
10.2 CHECKING BEFORE OPERATION ４－１６
10.3 IRREGULAR MAINTENANCE ４－１７
10.4 MAINTENANCE EVERY 50 HOURS ４－３６
10.5 MAINTENANCE EVERY 100 HOURS ４－３８
10.6 MAINTENANCE EVERY 250 HOURS ４－３９
10.7 MAINTENANCE EVERY 500 HOURS ４－４１
10.8 MAINTENANCE EVERY 1000 HOURS ４－４６
10.9 MAINTENANCE EVERY 1500 HOURS ４－４８
10.10 MAINTENANCE EVERY 2000 HOURS ４－４９
SPECIFICATIONS ５－ １
1. SPECIFICATION LIST ５－ ２
2. SPECIFICATION DIMENSIONAL DRAWING ５－ ３
3. RATED TOTAL LOAD CHART ５－ ４
4. WORKING RADIUS AND LIFTING HEIGHT ５－ ７
SEARCHER HOOK ６－ １
1. SEARCHER HOOK EACH SECTION ６－ ２
2. MOMENT LIMITER DISPLAY UNIT ６－ ３
3. OPERATION ６－ ５
4. INSPECTION AND MAINTENANCE ６－ 8
4.1 LEGAL INSPECTION ６－ 8
4.2 CONSUMABLES ６－ 8
4.3 INSPECTION AND MAINTENANCE LIST ６－ 8
4.4 MAINTENANCE PROCEDURES ６－ 9
INTRODUCTION
1. INTRODUCTION 1- 2
2. FOR SAFE USE OF MACHINE 1- 3
3. MACHINE OVERVIEW 1- 4
4. QUALIFICATION FOR OPERATION 1- 6
5. TERMINOLOGY 1- 7
1. INTRODUCTION
Thank you for purchasing our Crawler Crane “LC383M-5”.
This manual is a guidebook for safe and effective use of this machine.
This manual describes the procedures for proper operation and maintenance of the machine.
Warnings and precautions defined in this manual shall be observed for safety.
Many of the accidents are caused by failure to observe the basic precautions for operation,
inspection and maintenance.
Be sure to read this manual and understand the procedures for machine operation,
inspection, and maintenance thoroughly before performing any operation of this machine.
Failure to observe the basic precautions defined in this manual may lead to hazardous
accidents.
Failure to use this machine properly can lead to serious personal injury or death.
Operators and maintenance personnel must always read this manual prior to
operation or maintenance of this machine.
Keep this manual at a designated place for reference when necessary. All
personnel who work with this machine are to carry out periodic reference to the
manual.
• Only those who have a thorough understanding of the fundamental procedures
provided in this manual are allowed to operate this machine.
• Keep this manual handy for reference when necessary.
• Should you lose or damage this manual, contact Maeda or our sales service
agency immediately for ordering a new manual.
• This manual should always accompany this machine upon transfer of the machine
to the next owner. However, when the machine is sold to a third party without any
prior advice to us, we are not liable for any warranty.
• This manual has adopted data that was available at the time of the creation of the
manual.
The contents of this manual, including maintenance specifications, tightening
torque, pressure, measuring method, adjustment value, and illustrations, are
subject to change without notice.
Machine maintenance may be subject to revisions. Always obtain the latest
information from Maeda or our sales service agency before performing
maintenance of this machine.
For safety instructions, see “2. For Safe Use of Machine” on page 1-3 and “Safety”
on page 2-1.
2. FOR SAFE USE OF MACHINE
This manual classifies the risks into the following three categories to present the details of the safety labels in a easy-to-understand manner.
This denotes that there is an imminent hazard which will cause serious personal injury or death.
The method of hazard circumvention is stated.
This denotes that there is a hazard which can cause serious personal injury or death.
The method of hazard circumvention is stated.
This denotes that there is a potential hazard which may cause minor or moderate personal injury or serious damage to this machine.
The method of hazard circumvention is stated.
This manual also provides the following to indicate what must be observed for the sake of the machine and what will be of help.
This denotes that failure to handle the machine properly may damage the machine or shorten its life.
This denotes helpful information.
Not only procedures for operation, inspection, and maintenance of this machine described in this manual but also safety precautions that may pertain to the case where this machine is only used for specified tasks.
Every circumstance incidental to use of this machine is unforeseeable, and therefore, cautions given in this manual and on this machine do not necessarily cover every safety-related issue.
Necessary safety actions should be taken under your responsibility if operation, inspection, and maintenance in a situation that is not described in this manual are performed.
Even in the above case, never attempt work or operations that this manual prohibits doing.
CAUTION
3. MACHINE OVERVIEW
3.1 SPECIFIED OPERATIONS
This machine is for use with the operations listed below. • Crane operation
• Pick & Carry operation
This machine is a mobile crane which consists of a crawler type carrier and an upper structure of a boom type crane.
This self-propelled crane is capable of moving (travelling) at the worksite and lifting an object weighing within the rated total load for normal crane operation or pick and carry operation.
3.2 MACHINE CONFIGURATION
This machine is comprised of the units listed below. [1] UNDERCARRIAGE
This is comprised of a travelling gear and blade. [2] UPPER STRUCTURE (CRANE)
This is comprised of an engine, travelling operation unit, crane operation unit, telescoping system, derrick system, slewing system, hook block, and winch system.
[3] SAFETY DEVICE
This is comprised of the following parts and devices: Over hoist detector/automatic stop device, three-winding stop alarm/automatic stop device, moment limiter (working envelope limited), slinging rope detachment protector, hydraulic safety valve, telescoping cylinder hydraulic automatic locking device, derricking cylinder hydraulic automatic locking device, alarm buzzer, machine tip-over alarm device, level, working status lamp, crane lock lever and travel lock bar.
3.3 MACHINE FUNCTIONS
[1] UNDERCARRIAGE
• The carrier is equipped with crawlers which enables this machine to enter into rough or soft terrain. • 2 travel lever operation enables not only direction changes, forward, backward, and right/left but pivot
and spin turns.
[2] UPPER STRUCTURE (CRANE)
• The upper structure allows continual 360 degree rotation.
4. QUALIFICATION FOR OPERATION
• A high incidence of occupational accidents during crane operation are reported.
Be aware that experienced engineers are no exception.
• Warnings and precautions defined in this manual shall be observed for safety assurance
during operation of the machine.
4.1 QUALIFICATION FOR CRANE OPERATION
Only personnel that have obtained the required license or training stipulated by laws and regulations applicable to the place of use are qualified to operate this machine.
5. TERMINOLOGY
5.1 DEFINITIONS OF TERMS
[1] RATED TOTAL LOAD
This is the maximum load that can be applied according to boom length and angle. The load includes the mass (weight) of hoisting accessories (hooks) slings, chains and ropes etc. [2] LIFTED LOAD
This is a load derived by subtracting the mass (weight) of hoisting accessories (hooks) and sling etc, from the rated total load, which is a maximum load for hoisting.
[3] WORKING RADIUS
This is a horizontal distance between the axis of slewing and the hook center.
[4] BOOM LENGTH
This is a distance between the boom primary pin and the sheave pin of the end boom.
[5] BOOM ANGLE
This is an angle which the boom forms from horizontal.
[6] LIFTING HEIGHT ABOVE GROUND
5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT
• The diagram of working radius and lifting height shows the relationships the working radius of
this machine, boom angle, and lifting height above the ground with no object hoisted. The diagram has been made allowing for no deflection in the boom.
• The boom (3) in the diagram of working radius and lifting height represents a state that half of
the “ mark” passes boom (2).
1. Point A denotes a boom angle and point B denotes a lifting height above ground in the figure at right.
The same working radius is applied to points A and B.
5.3 RATED TOTAL LOAD CHART
• All the values provided in the rated total load chart are based on the assumption that the
machine is placed on a level and firm surface.
• The values in the rated total load chart are determined based on the working radius allowing
for deflection that is developed when load is applied to the boom.
• When extending boom (2) even if only slightly, crane operation should proceed to the extent of
performance of “Boom (2)”.
• When extending boom (3) even if only slightly, crane operation should proceed to the extent of
performance of “Boom (3)”.
• When half of the “ mark” on boom (3) passes boom (2), crane operation should proceed to the extent of performance of “Boom (4)”.
• If the working radius exceeds that stated in the table even if only slightly, crane operation
should proceed with respect to the rated total load corresponding to the working radius in the following table.
• The rated total load is a load including the mass of a hoisting accessory (hook: 30kg).
Maeda, Please check 8.71m Boom on above chart, it
should say Stationary and not Pick and Carry
ＬＣ３８３Ｍ－５ Ｒａｔｅｄ Ｔｏｔａｌ Ｌｏａｄ Ｃｈａｒｔ
3.18m boom 5.03m boom 6.87m boom 8.71m boom Working radius
(m) Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry
The rated total load chart provides the maximum loads that the crane is capable of hoisting objects in parallel with the length of the boom. The loads are specified by working radius.
[1] BOOM LENGTH
The following figures illustrate the condition of the booms, “(1) 3.18m Boom”, “(2) 5.03m Boom”, “(3) 6.87m Boom”, and “(4) 8.71m Boom” in the preceding boxes in the rated total load chart.
1. “(1) 3.18m Boom”: All the booms are retracted.
2. “(2) 5.03m Boom”: With booms (3), and (4) retracted, boom (2) is fully extended.
Boom (2) is to apply to crane operation with boom (2) extended even if only slightly.
3. “(3) 6.87m Boom”: With boom (2) fully extended, booms (3) and (4) are extended midway (half of the
“ mark” passes boom (2)).
5. “(4) 8.71m Boom”: All the booms are fully extended.
6. Necessary information for service
The following information is required for us or our sales service agency at the time of requesting repair service or ordering spare parts.
Machine serial number engraved on plate
Located at the lower right part of canopy.Information of EPA
EPA plate is located on radiator bracket.
SAFETY
1. BASIC PRECAUTIONS 2- 2
2. DRIVING RELATED PRECAUTIONS 2- 8
3. TRANSPORT PRECAUTIONS 2-24
4. TOWING PRECAUTIONS 2-25
5. MAINTENANCE PRECAUTIONS 2-26
6. SAFETY LABEL LOCATIONS 2-33
All the safety precautions defined in this manual should always be read and observed.
1. BASIC PRECAUTIONS
Failure to operate or maintain this machine properly can lead to serious personal injury or death. Be sure to read this manual and each safety label thoroughly before performing any operation or maintenance of this machine and observe the safety precautions.
1.1 PRECAUTIONS FOR BEFORE STARTING OPERATION
OBSERVE THE MANUAL AND SAFETY LABELS
• Study and understand this manual as well as the safety labels labeled on various part of this Machine. Any attempt to drive/operate without understanding it fully may result in incorrect operation that may cause personal or equipment accidents.
• Fully understand the proper use and inspection/maintenance procedures, and exercise safe working practices.
• Make sure this manual and the safety labels fixed on various part of this Machine are legible at all times.
Whenever illegibility or loss occurs, order from us or our sales service agency and put the safety label back to the original location.
DRIVING LICENSE
• Licenses or training certificates are necessary to drive this Machine. Always obtain a license or training certificate before driving.
See “Introduction 4. Qualification for Operation” for details
• The drivers are requested to receive education and training in the handling methods and other subjects from the applicable office, and obtain sufficient driving operation skills before work.
COMMIT TO SAFE OPERATION
• Obey the instructions and signs given by the manager and work supervisor, and observe safety first during the work.
• Obey the crane work basics during operation.
• Before starting driving or work, always carry out the inspections first. • Do not work under bad weather for instance strong wind, thunder or mist.
• Do not drive under any condition when you are overtired, have drunk alcohol or after taking a sedatory drug.
• Obey all of the workplace rules, safety regulations and operation method sequences during driving operations and inspection/maintenance.
• Pay attention to surrounding conditions and pedestrians at all times when driving or working.
If pedestrians approach the working area, abort working and take action to warn and remove them from the area.
• When driving, be mentally prepared for any unexpected situations so that you can take the appropriate action immediately.
• Do not attempt any use outside of the capabilities and purposes described in this manual under any circumstance.
• Observe the designated rated total load and working range when driving.
1.2 PREPARATIONS OF SAFETY OPERATION
PROVIDE SAFETY DEVICES FOR SURE
• Check that all guards, covers,and mirrors are attached properly. Repair immediately if damaged. • Understand how to use the safety devices correctly and use properly.
• Do not detach any safety device under any circumstance. Keep control to achieve proper operation at all times.
• Improper use of safety devices can lead to serious bodily accidents. • Do not rely solely on safety devices.
PREPARE FOR ABNORMALITY
• Carry out secure inspections and services, and be careful to prevent accidents before they happen.
• Whenever you feel an abnormality of the Machine, abort working immediately, ensure safety and report to the manager.
• Assign in advance a person to take care of the solution to prevent secondary accidents.
• Do not drive the Machine when fuel or hydraulic oil is leaking from the Machine. Report to the manager any abnormality, and fully repair the fuel/hydraulic oil leak before use.
The fuel for this Machine is diesel oil. Be especially careful of any fuel leak.
• Before leaving the Machine, lower the hoisted load to the ground, stop the engine and remove the engine ignition key.
TEMPORARY STORAGE WHEN ABNORMALITY IS FOUND WITH MACHINE
if the Machine is found to have an abnormality and is therefore placed in storage awaiting service, apply the following measures to notify all persons in the office that its use is prohibited due to failure.
• Attach warning tags on the operation lever and other applicable parts.
Clearly write the information regarding the abnormality. The name and contact of the storage manager, and the term of storage.
• Make sure the machine cannot move when parking, by placing blocks under the rubber tracks.
• Remove the engine ignition key and take it with you.
WEAR PROTECTIVE EQUIPMENT AND CLOTHES SUITABLE FOR WORK
• Always wear a helmet and safety shoes. Make sure to wear goggles, mask, gloves, hearing protectors, and safety belt suitable for the relevant working condition.
• Long hair coming out under helmet can be caught in machine. Make sure to tie to prevent accident.
USE OF MACHINE THAT WAS RENTED OR PREVIOUSLY USED BY SOMEONE ELSE
Check the following subjects in writing before using any Machine that was rented or previously used by someone else. In addition, check the inspection record table for the maintenance conditions such as the periodic inspections.
(1) Crane capacity
(2) Crane maintenance condition
(3) Behavior and disadvantage unique to the crane (4) Other subjects that require attention when driving
(a) operating condition of the brakes, clutches and others
(b) Presence/absence of lights and their condition. Check lights of rotating lamps (c) Operation condition of hook, winches, boom, outriggers and other related items
KEEP MACHINE CLEAN
• If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean.
• If water gets into the electrical system, there is a hazard that it will cause malfunctions or miss-operation. Do not use water or steam to wash the electrical system (sensors, connectors).
KEEP OPERATOR’S COMPARTMENT CLEAN
• When entering operator’s compartment, always remove all mud and oil from the soles of your shoes. If you operate the pedal with mud or oil on to your shoes, your foot may slip and this may cause a serious accident.
• Do not leave parts or tools lying around the operator’s compartment.
• Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
• Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.
• Do not use cellular telephones inside operator’s compartment when driving or operating the machine.
PROVISION OF FIRE EXTINGUISHER AND FIRST AID BOX
Always observe the following to prepare for injuries and fires.
• In case of fire, decide on the fire extinguisher storage location and install one, fully read the attached label for its uses and be prepared for fighting any emergencies.
• Decide on the location to store the first aid box. Inspect the first aid box periodically and replenish the contents as necessary.
• Consider the measures to take upon an injury or fire.
1.3 PRECAUTIONS FOR FIRE PREVENTION
ACTION IF FIRE OCCURS
If a fire occurs, escape from the machine as follows. • Turn starter switch OFF to stop engine.
• Use the handrails and steps to get off the machine. FIRE PREVENTION AND EXPLOSION PREVENTION • FIRE CAUSED BY FUEL, OIL, OR ANTIFREEZE.
Fuel, oil, or antifreeze are particularly flammable and can be hazardous. To prevent fire, always observe the following:
• Do not smoke or use any flame near fuel oil,or antifreeze. • Stop the engine before refueling.
• Do not leave the machine while adding fuel or oil. • Tighten all fuel and oil caps securely.
• Do not spill fuel on overheated surfaces or on parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.
• When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire, so do not use them.
• Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
• Use well-ventilated areas for adding or storing oil and fuel.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
• When carrying out grinding or welding work on the chassis, move any flammable materials to a safe place before starting.
• FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, battery, or inside the covers.
• FIRE COMING FROM ELECTRIC WIRING
Short circuit in the electrical system can cause fire.
• Always keep electric wiring connections clean and tightened. • Check the wiring every day for looseness or damage. Tighten any
loose connectors or wiring clamps. Repair or replace any damaged wiring.
• FIRE COMING FROM HYDRAULIC LINE
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
• EXPLOSION CAUSED BY LIGHTING EQUIPMENT
• When checking fuel, oil, battery, electrolyte, window washer fluid, or coolant, always use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause serious injury.
1.4 PRECAUTIONS WHEN GETTING ON OR OFF
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
• Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine.
• To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe) to ensure that you support yourself.
• Before getting on or off the machine, check the handrails and steps (including the track shoe). If there is any oil, grease, or mud on the handrails and steps (including the track shoe), wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.
• Do not grip the control levers, or lock lever when getting on or off the machine.
• Never climb on the engine hood or covers where there are no non-slip pads.
• Do not get on or off the machine while holding tools in your hand. • Never jump on or off the machine, Never jump on or off a moving
machine.
• If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
PRECAUTIONS WHEN LEAVING OR STANDING UP FROM OPERATOR’S SEAT
• Before standing up from operator’s seat (such as when adjusting the operator’s seat), always store the crane completely, set lock lever (1) securely to the LOCK position (L), then stop the engine. If you accidentally touch the control levers or pedals when they are not locked, there is a hazard that the machine may suddenly move and cause serious injury or property damage.
1.5 OTHER PRECAUTIONS
PRECAUTION NOT TO GET CAUGHT IN THE MACHINE
Around the upper structure and craning devices, movement of the derricking cylinder and/or winch make the opening space vary. When one becomes caught in such an opening, it may result serious personal injury or death.
Always keep persons away from any rotating or telescoping parts. Especially, avoid putting oneself or your body into locations as below: • Clearance between boom and upper structure
• Clearance between boom and derricking cylinder • Clearance between winch drum and wire rope • Clearance between each sheaves and wire rope
DO NOT MODIFY
Do not modify the Machine without our written consent under any circumstance. Especially, welding work which can damage safety devices badly.
Any modification raises a safety issue, so consult us or our sales service agency beforehand.
We cannot be held responsible for any bodily accident or failure caused by a modification that was performed without consulting us.
ATTACHMENT INSTALLATION
• When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact our sales service agency for advice.
• Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Maeda.
• When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual.
CAB WINDOW GLASSES
• The roof window and right side window are made of organic glass (polycarbonate), and as such it is apt to break easily when receiving damage on the surface, thereby deteriorating its protective characteristic. If there is a crack or damage caused by a fallen object, or when any sign of damage is noticed, replace it with a new window.
BEWARE OF EXHAUST GAS
2. DRIVING RELATED PRECAUTIONS
2.1 PRECAUTIONS FOR JOBSITE
SAFETY AT JOBSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
• When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
• Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks.
• Flatten the inclination of the working site as much as possible before starting work.
• When working over the roadway, enforce a no entry zone, for instance, placing guides or surrounding with barriers, to ensure the safety of the traffic vehicles and pedestrians.
• Enforce a no entry zone to prevent people from entering the working site and apply measures to prevent people from approaching. Attempting to approach a moving Machine may result in a collision by contact or pinching, and may result in serious bodily accidents and deaths.
• When travelling or operating in shallow water or on soft ground, check the sharpness and condition of the bedrock, and the depth and speed of flow of the water before starting operations.
• Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such area. If the ground collapses under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in this area.
• When working on embankments or near excavated ditches, there is a hazard that weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.
ENSURE GOOD VISIBILITY
This machine is equipped with mirrors to improve the visibility, but even with mirrors, there are places, which cannot be seen from the operator’s seat, so always be careful when operating.
When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious personal injury.
When operating or travelling in places with poor visibility, always observe the following items strictly. • If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay
careful attention to the signs and follow the instruction of the flagman. • The signals should be given only by one flagman
• When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set up additional lighting in the area.
• Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
• Check the mirror on the machine before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility.
SIGNALMAN’S SIGNAL AND SIGNS
• Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
• Only one signalman should give signals.
BEWARE OF ELECTRICAL CABLE ABOVE
• Do not let the Machine come in contact with electrical cables overhead.
High voltage cables may inflict electrical shock by just approaching. • Persons who sling are likely to suffer electrical shocks.
Always observe followings to prevent accidents.
• If the boom or the wire ropes may contact an electrical cable in the workplace, consult the electricity company and make sure that the measures (measures for instance placement of a guard personnel or application of wrap tubes and warning tags to the electrical cable) stipulated by the related regulations are taken before starting work.
• Put on rubber soled shoes and rubber gloves, and be careful that the body parts unprotected by rubber or other insulation do not contact the wire rope or the Machine frame.
• Place a guide and let him/her watch so that the boom, wire rope or Machine frame does not go to close to the electrical cable.
Before doing so, decide on the emergency signs and other necessities.
• Ask the electricity company for the voltage in the electrical cables in the working site.
• Ensure the offset distances (safe distance) shown in the following table between the boom/Machine frame and electrical cables. Also check local regulations as they may require larger safety factors.
Voltage of
MEASURES WHEN CHARGE ACCIDENT OCCURS
If an electrical charge accident occurs, do not panic and stay calm, apply the solution in the following sequence.
1. Report
Immediately report to the electricity company or related management company, and receive instructions to stop the power transmission, emergency procedures and any related procedures. 2. Evacuation of related personnel from vicinity of Machine
Remove all personnel including workers from vicinity of the Machine to prevent any secondary disasters.
Personnel who suffered electrical shock by holding a sling rope, guide rope or other conductors when the Machine was charged should evacuate by his/her own effort.
Do not try to help such persons. Otherwise a secondary electrical shock accident can occur. 3. Emergency procedure
Take the solution by the following sequence in case of urgency where personnel received electrical shock because the Machine was charged.
(1) If the Machine can be operated, immediately move the Machine away from the contact and out of the range of the cause of the charge. Be careful not to snip the distribution power cable.
(2) Evacuate the Machine completely away from the cause of the charge, make sure the Machine is not charged, rescue the electrically shocked personnel and immediately carry to the hospital. 4. Measure after accident
After the accident, do not put the machine back into service. Attempting to do so may cause unexpected accidents and enhances failures. Ask us or our sales service agency for repair.
CAUTIONS WHEN WORKING WITH THE CRANE IN A LOCATION WITH HIGH OUTPUT OF MICROWAVE EMISSION
Working with the crane near a high output of microwave emission equipment such as radar or TV/radio broadcast antenna may causes the crane construction to be exposed to the microwave and generates induced current, therefore it is very dangerous. In addition, the machine electronics may become disturbed.
Establish grounding between the Machine frame and the ground when working in such location. In addition, slingers are requested to wear rubber boots and rubber gloves since risk of electrical shock by contacting parts such as the hook or wire exists.
BEWARE OF ASBESTOS DUST
Inhalation of air containing asbestos may result in lung cancer. This Machine does not use any asbestos, but asbestos may be contained in the wall, ceiling or other part of construction within the work area of this Machine. In addition, be careful of the followings when working with a material that may be using asbestos.
• Put on designated dust free mask and/or other equipment as necessary.
• Do not use compressed air for cleaning.
• Spray water when cleaning to prevent asbestos dusts from flying into air.
• Always work at a windward location when driving the Machine at a site that may contain asbestos dusts.
• Enforce a restriction zone to prevent people from entering the working site.
2.2 PRECAUTIONS WHEN ENGINE STARTING
PRECAUTIONS FOR WARNING TAG
If there is a warning tag hanging from working equipment control lever, do not start the engine or touch the levers.
Do NOT operate
When this tag is not being used, keep it in the storage compartment. If there is no storage compartment, keep it in the operation manual case.
INSPECTION BEFORE STARTING ENGINE
Check the instructions in "Operation 3.1 Checking Before Operation" as well as the following, without starting the engine and before starting work every day:
Omitting these inspections may result in serious bodily accidents. • Do not fail to perform the check before operation.
• Remove all dirt from the surface of the window glass to ensure a good view.
• Remove all dirt from the surface of the lens of the working lamps, and check that they light up correctly. • Check/refill engine coolant, fuel and the engine oil pan, and check for air cleaner clogging or electrical
circuit breakage.
• Adjust the operator’s seat to a position where it is easy to carry out operations, and check that there is no damage or wear to the seat belt or mounting clamps.
See “Operation 3.1.2 Checking Before Starting Engine (Adjusting Operator’s Seat)” for details. • Adjust the mirrors so that the rear of the machine, and winch drum can be seen clearly from the
operator’s seat.
See “Operation 3.1.2 Checking Before Starting Engine (Adjusting Mirrors)” for details.
• Check pedals for piled up mad or alien substances which may disturb their movement, and remove, to ensure correct function.
• Check the operation of the instruments and gauges, and check that the control levers are all at the Neutral position.
Always repair if any of the above is faulty.
CHECKS BEFORE STARTING ENGINE
• Make sure no person or object is within the boom swing radius area before starting engine.
• Make sure no person is on, below or around the machine, and also that no person or object is within the boom swing radius area, before starting engine.
• Do not allow anyone apart from the operator to ride on the machine. • Start and operate the machine only while seated.
• Before starting engine, check that the control levers are all at the Neutral position.
• Before starting engine, check that lock lever (1) is in LOCK position (l).
• When starting the engine, sound the horn as a warning.
CAUTIONS UNDER COLD WEATHER
• Remove snow from and unfreeze the swing gear, boom and winch related parts, and check the movements before work.
• Warm up the engine and hydraulics. Attempting to operate the control levers and pedals without enough warm up causes the Machine to react poorly, and may result in unexpected accidents. • If the battery fluid is frozen, do not charge the battery or start the
engine using any other power source. Such an act may cause the battery to catch fire. Before charging or starting up using other power source, unfreeze the battery fluid and check that failures such as a battery fluid leak do not exist.
• After the end of the work, wipe off and apply wraps if substances such as condensation, snow or mud are stuck to the wire harness, connector (1), switches, sensors or similar part.
If the infiltrated condensation and/or similar substances freeze, the Machine may operate improperly upon its next use and cause unexpected accidents.
CAUTIONS WHEN STARTING UP USING BOOSTER CABLE
The wrong booster cable connection method may result in fire, so always observe the followings.
• When starting up the engine using a booster cable is attempted, always arrange 2 persons, one in the cabin and another with the battery.
• When starting using another Machine, be careful to prevent contact between the normal Machine and broken Machine.
• Keep the starter switch key of both the normal Machine and the broken Machine in OFF position when the booster cable is connected.
• Do not connect to wrong side [connecting (+) to (-), (-) to (+)] when connecting the booster cable.
• Start connecting from (+) terminal first, but start disconnecting from (-) terminal (ground) first.
• Connect the ground to the (-) terminal of the battery of the broken Machine when connecting the ground as the last procedure.
See “Operation 8.4.4 Starting Engine with Booster Cable” for details.
2.3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE
CHECKS BEFORE OPERATION
Omitting the inspections after starting the engine results in delay to notice the Machine abnormalities, and may result in bodily accidents and Machine damages.
Execute inspection in a wide location with no obstacle. In addition, be sure to prevent people from approaching nearby the Machine.
• Check that the movement of the machine matches the display on the control pattern card. If it does not match, replace it immediately with the correct control pattern card.
• Inspect the equipment operation conditions, Machine travelling conditions, winch winding up and down, boom derricking, and crane operation conditions such as extension, retraction and swinging. • Inspect the sound, vibration, heat and odor of the Machine, and check for instrument errors, air leaks,
oil leaks, fuel leaks, water leaks and other such factors. Be extra careful with fuel leaks.
• Always repair the broken part whenever an abnormality is found. Attempting to use without servicing may result in unexpected bodily accidents and/or Machine failures.
CAUTIONS WHEN MOVING FORWARD/BACKWARD OR CHANGING DIRECTION
To prevent serious injuries and fatal accidents, always execute the followings before moving the Machine.
• Set the Machine to the travelling posture shown in the right diagram. See “Operation 3.6 Machine Travelling Posture” for details. Do not travel when the hook block is not contained.
• Before travelling, set the machine so that sprocket (A) is behind the operator’s seat. If sprocket (A) is in front of the operator’s cab, the machine will move in the opposite direction from the operation of the levers (front and rear travel is reversed, left and right steering is reversed). Be extremely careful when operating the machine in this situation.
• Have the boom fully lowered and retracted. • Fix the hook block to the containment position.
For short distance travel, secure the hook block to the stowage position below the boom tip. For longer travel, secure it to the regular stowage wire rope at the front of the upper structure. • In an environment where anyone is around the machine, the
machine may smash or catch him/her, which results in death or serious injury.
Before starting to travel observe strictly as follows: • Always operate the machine only while seated. • Always fasten your seat belt.
• Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles.
• Before travelling, sound the horn to warn people in the area. • After starting to travel, check that the travel alarm correctly sounds. • If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other machines or people when turning or swinging the machine.
CAUTIONS WHEN TRAVELLING
Always observe the following to prevent serious injuries and fatal accidents when the Machine is travelling.
• Set the Machine to the travelling posture shown in the right diagram. See “Operation 3.6 Machine Travelling Posture” for details. • Do not attempt looking sideways or other dangerous acts when
driving.
• Do not: over speed, start/stop or swing suddenly, as such acts are dangerous.
• When travelling, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them.
• Avoid travelling over obstacles when possible. If the machine has to travel over an obstacle, keep travel at low speed. Never travel over an obstacle which makes the machine tilt strongly to one side. • When travelling on rough ground, travel at low speed and do not
operate the steering suddenly. There is a danger that the machine may turn over. The machine may lose its balance, or may damage the machine or structures in the area.
• When passing over bridges or structures, check first that the structure is strong enough to support the weight of the machine. When travelling on public roads, check first with the relevant authorities and follow their instructions.
• When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate slowly and be extremely careful not to let the crane hit anything.
BE CAREFUL WHEN TRAVELLING OVER SLOPES
ALWAYS observe the following to prevent serious injuries and fatal accidents when travelling over a slope for unavoidable reasons. • For travelling on a slope, always keep the correct travelling posture
with the hook block secured to the hook block stowage wire rope in the front of the upper structure. When the hook block is temporary stowed below the boom tip, it may become slack during travelling.
See “Operation 3.6 Machine Travelling Posture” for details. • In a 10 degrees or more slope, use reverse travelling to climb it and
forward travel for descend. Always direct the machine front to the downward of the slope. Where forward travelling to climb up and reverse travelling for descend is used, it makes the machine unstable and brings risks of overturning or drifting.
• Always travel straight up or down a slope. Traveling at an angle or across the slope is extermely dangeropus.
• Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again.
• When traveling downhill, lower engine speed, keep the travel lever close to the neutral position, and travel at low speed.
• Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that the machine may slip. • If the engine stops when the machine is traveling on a slope, move
BE CAREFUL OF TIPPING ON UNSTABLE GROUND
Always observe the followings to prevent serious injuries and fatal accidents when travelling over unstable ground for any reason.
• Do not enter any soft ground area. The Machine is difficult to remove from this type of ground. • Ground near a cliff, roadside or a deep gully may be unstable, so avoid going near such ground as
much as possible.
The Machine may tip or fall when the ground loosens due to mass and/or vibration of the Machine. Be especially careful that the ground may have loosened after rain, use of dynamite or earthquake. • Avoid going near earth fills or the vicinity of excavated gutters that are instable.
Crumbling caused by mass and/or vibration of the Machine may cause the Machine to tilt.
CAUTIONS WHEN SNOW COVERED OR FROZEN
Always observe the following to prevent serious injuries or fatal accidents when travelling over snow covered ground or frozen roads for any reason.
• Snow covered ground and frozen roads can cause slips even when the inclination is slight, so decrease the speed when travelling and avoid starting, stopping, and swinging suddenly. Uphill and downhill are especially likely to cause slips and thus dangerous.
• The ground of a frozen road becomes soft when the air temperature rises and causes the Machine travel and other operations to be unstable. Be very careful.
• During cold weather, check that the load to be hoisted is not frozen or stuck to the ground or any other surface. Attempting to hoist without knowing the load is frozen or stuck to the ground or other surfaces is dangerous.
• Do not touch the metal surface with any part of your body, such as a finger or hand during cold weather.
Attempting to contact a metal surface of the Machine under harsh cold weather may cause the skin to stick to the metal surface.
• Remove snow and/or ice from the Machine that causes the safety nameplates to be hard to read. Be especially careful to remove ice or snow that is on the boom and may fall.
CAUTIONS WHEN PARKING
• Park the machine on firm, level ground.
• Select a place where there is no hazard from falling rocks, landslides, or of flooding if the land is low.
• Set the Machine to the travelling posture shown in the right diagram. • Fully lower and retract the boom.
• Fix the hook block to the containment position.
When parking for a short time, secure the hook block to the stowage position below the boom tip. For longer periods of parking, secure it to the regular stowage wire rope at the front of the upper structure. • Where it is un-avoidable to park the machine on a slope, strictly
observe the following:
•. Fully lower and retract the boom
• Fix the hook block to the containment position.
When parking for short periods, secure the hook block to the stowage position below the boom tip. For longer periods of parking, secure it to the regular stowage wire rope at the front of the upper structure.
• Set the front of the machine (blade) on the downhill side. Then dig it into the ground.
• Put blocks under the tracks to prevent the machine from moving. • When you leave the machine, strictly observe as follows:
• Set lock lever (1) to LOCK position (L), and then stop the engine. • Always remove the key, take it with you, and leave it in the
2.4 PRECAUTIONS WHEN WORKING WITH CRANE
INSPECTION BEFORE STARTING WORK
Check that the safety devices and crane operate properly.
• Operate each of the operation levers, pedals and switches under no load, and check that operations take place without abnormality.
Repair immediately if any abnormality exists.
• Check that the safety devices such as the moment limiter, over hoist detector device and three-winding stop alarm device activate properly.
CAUTIONS WHEN HANDLING MOMENT LIMITER
• Use/store the moment limiter under the following ranges of ambient temperature. Temperature of use: -10 to 50 degrees C Storage temperature: -30 to 70 °C
• Avoid direct sunlight so that the temperature of the atmosphere surrounding the moment limiter does not exceed the above range.
• Avoid locations with a strong acid or alkaline atmosphere as much as possible. Otherwise, unexpected failures may occur.
• Avoid impact to the moment limiter body, for instance colliding with an object. Doing so may damage the case and result in failures and improper operations.
• Avoid excessive pressure to the panel sheet of the moment limiter body or pushing with a sharp object such as the tip of a screwdriver. Doing so may damage the panel sheet and could result in failures and improper operations.
• Do not remove the case cover or panel sheet from, or disassemble the moment limiter body. Doing so may damage the case and/or panel sheet and could result in failures and improper operations.
CAUTIONS WHEN SETTING UP MOMENT LIMITER
• The moment limiter calculates the moments assuming the Machine is level.
If you work with the crane when the Machine is not level, warnings and alarms are not issued even when the rated total load is near. Always use the level to ensure that the machine is not at an angle. • Before using the moment limiter, check that the boom angle display, boom length display and real load
display are displayed correctly following the crane movements. Attempting to use without the correct display results in failure to obtain the correct measurement and may result in serious bodily accidents caused by reasons such as tipping over and/or breakage of the machine.
• Always make sure the fall mode setting of the moment limiter matches with the wire rope fall of the crane. Attempting to use unmatched wire rope falls may results in failure to obtain the correct measurement and could result in serious accidents caused for instance by a breakage of the wire rope. • Do not change the setting when measuring with the moment limiter. Doing so could result in failure to
obtain the correct measurement and may result in serious bodily accidents caused by reasons such as tipping over and/or breakage of the machine.
PRECAUTIONS WHEN DECIDING THE CRANE OPERATION SITE
Always place the machine on the level and solid ground.
Crane operation is dangerous when the machine is placed in an area such as below: • Temporary asphalt pavements
• Thin concrete pavements • Stone pavements
• Where the surface looks solid but the soil under it is soft, or the soil below a pavement has been washed by water and become hollow.
PRECAUTIONS FOR CRANE OPERATION ON A SLOPE
Where a crane operation on a slope is un-avoidable, firstly fill some soil (B) to prepare a level and solid platform, and then place the machine on it, so that overturning is prevented.
Unless this is done the crane is not placed level and attempting to hoist will mean that the moment limiter (over-load detector) will not work accurately, as well as a un-foreseeable force to the machine which may overturn or damage it.
FOLLOW INSTRUCTIONS AND SIGNS WHEN WORKING
• When working with the crane, appoint a work supervisor and agree signals beforehand, and obey the work supervisor and his signals during work.
• When working at a location where any areas are out of sight of the driver, be especially careful to follow the instructions and signals of the work supervisor and pay attention when driving.
• When working with the crane, the clearance between the boom and the upper structure and also the gaps between the movable parts of the derrick cylinder may catch body parts such as an arm or finger. The driver is requested to make sure no one is within the working radius of the crane before operating crane.
CAUTIONS UNDER COLD WEATHER
• Remove snow from and unfreeze the swing gear, boom and winch related parts, and check the movements before work.
• Check the operation of winch brake.
• Warm up the machine. Attempting to operate the operation levers, pedals and switches without enough warm-up time causes the Machine to react dull, and may result in unexpected accidents.
For details of warm up operation, see “Operation 3.3.1 Engine Warm Up”.
• Accumulation of snow within the working range of the crane can cause the suspended load to overturn. Workers may also trip over. Remove snow sufficiently before starting crane operation.
• If the load to be hoisted is stuck to the ground because it is covered with snow or frozen, do not force hoisting of the load. Thoroughly remove the snow or unfreeze before crane operation.
• After ending work, wipe off and apply wraps if substances such as condensation, snow or mud are stuck to the wire harness, connector (1), switches, sensors or similar parts.
PAY ATTENTION TO WEATHER INFORMATION
• During a thunderstorm, risk of lightning exists, so abort working with the crane, immediately lower the load and contain the boom.
• Exposing the hoisted load to wind causes the load to swing and the Machine to become unstable, this is dangerous. Immediately lower the load and contain the boom when the wind is causing the load to swing.
• If the maximum instantaneous wind speed is 10 m/s or greater, abort working with crane, immediately lower the load and contain the boom.
• Even when the maximum instantaneous wind speed is below 10 m/s, the bigger the hoisted load, the higher the hoisted load position, and the longer the boom, the wind effect will increases accordingly. Be very careful during work.
• When the boom is extended full or nearly full, take notice of that the winch wire ropes and electrical cable for signals are also effect by the wind. In addition, the wind speed may increase when it blows through a high-rise building. Thus, be very careful when working near high-rise buildings.
• When a load such as a steel plate that has a large area exposed to wind is being hoisted, the wind arriving from front/rear/side of the boom may cause the Machine to tip or damage the boom. Be very careful when working.
• In a condition where wind blows to the front face of the boom, the higher the boom is raised, the more you may run a risk of overturning backward. Be very careful when working in such conditions. • When an earthquake occurs, abort working and wait until the earthquake is over.
The following table indicates approximate relation between the wind speed and wind effect. The wind speed mentioned in the weather forecast is mean wind velocity (m/s) during 10 m at 10 m above the ground.
Force Wind Speed (m/s) Effect On Land 0 Less than 0.3 Smoke rises vertically.
1 0.3 - below 1.6 Wind motion visible in smoke. 2 1.6 - below 3.4 Wind felt on exposed skin.
3 3.4 - below 5.5 Leaves and smaller twigs in constant motion.
4 5.5 - below 8.0 Dust and loose paper raised. Small branches begin to move. 5 8.0 - below 10.8 Smaller trees sway. Some foam and spray.
6 10.8 - below 13.9 Large branches in motion. Whistling heard in overhead wires. Umbrella use becomes difficult. 7 13.9 - below 17.2 Whole trees in motion. Effort needed to walk against the wind. 8 17.2 - below 20.8 Twigs broken from trees. Progress impeded.
9 20.8 - below 24.5 Light structure damage. Slates blown off.
CAUTIONS WHEN SLINGING
• Check the following before hoisting a load.
Attempting to hoist the load without checking may result in serious bodily accidents by dropping of the load or tipping of the crane.
• Observe the values in the rated total load chart. • Hoist from the center of gravity of the load.
• Check that the wire ropes of the hook block are perpendicular to the ground.
• When the load leaves the ground, stop winding up the load and check whether the load is stable. • Before hoisting a load, always check whether the sling wire rope "retainer device" of the hook block is
hanging securely If not the wire rope may leave the hook block and cause the load to fall and results in a serious accident.
• Larger sling rope angles when hoisting the load increases the force on the sling rope even when the load weight is unchanged, and can cause the sling rope to snap. Be careful when slinging in order to prevent excessive force to the sling rope.
• Do not hoist more than 1 load at a time.
This could cause the hoist bracket to hit and damage the other hoisted load, the loads may move and lose balance and cause tipping, or some other cause of a serious accident.
Do not hoist more than one load even if the total is within the rated total load. • Hoisting of lengthy loads may cause the load to lose balance and is dangerous.
In case of lengthy loads, hoist vertically by using a clamp, or achieve balance of the hoisted load by applying a rope to both ends of the load.
CAUTIONS WHEN HANDLING WIRE ROPE
• The wire rope wears down as the time passes, so inspect every time before work, and replace immediately if at or beyond the replacement standard.
At the same time, inspect the sheave at the tip of the boom and the sheave of the hook block. Damaged sheaves accelerate the damage of the wire ropes.
• Use the wire ropes specified by us.
• Wire rope breakage causing protruding wires may injure your hands. Always put on leather gloves when handling the wire rope. • Handling worn and damaged wire may cause injury from wire
splinters.
• Do not use any wire rope of which any of the followings apply. • 10% or more of the wires (except the filler wires) in one twist of the
wire rope are snapped off.
• The wire rope diameter wear is beyond 7% of the nominal diameter.
• Is kinked.
